Relay with sealed contact switch modules



April 21, 1970 .1. c. M AYER 3,503,130

RELAY WITH SEALED CONTACT SWITCH MODULES Filed June 14, 1968 3 Sheets-Sheet l INVENTOR JOSEPH c. MAYER BY 21 m. 7.

ATTORNEY April-21,1970 I J. c. MAYER 3,508,180 RELAY WITH SEALED CONTACT SWITCH MODULES 7 Filed June 14, 1968 v v 5 Sheets-Sheet 2 INVENTOR JOSEPH c. MAYER ATTORNEY Aprn21,197o J. -.MAYER 3,508,180

I RELAY WITH SEALED CONTACT SWITCH MODULES Filed June14, 1968 3 Shets-Sheet s INVENTOR JOSEPH C. MAYER msmnuy 7 ATTORNEY United States Patent 3,508,180 RELAY WITH SEALED CONTACT SWITCH MODULES Joseph C. Mayer, Milwaukee, Wis., assignor to Allen- Bradley Company, Milwaukee, Wis., a corporation of Wisconsin Filed June 14, 1968, Ser. No. 737,061 Int. Cl. H01h 1/66, 9/08 US. Cl. 335152 7 Claims ABSTRACT OF THE DISCLOSURE BACKGROUND OF THE INVENTION This invention relates to electrical relays, and more particularly to a relay having a plurality of magnetically responsive, separately demountable sealed contact switch modules, the relay having a structure which is highly versatile, compact, dependable and simple.

Sealed contact switches are known for their high reliability, high speed operation, and suitability for use in adverse operating environments. Such switches are of two general types. The basic or reed type of switch includes elongated overlapping reed members which act as both current and flux conductors. These reeds are usually enclosed in a sealed glass envelope filled with an inert gas. This type of switch is both reliable and very simple, but has a relatively low current capacity.

The other main type of scaled contact switch is similarly enclosed and operated, but uses a ditferent type of movable member to effectively separate the magnetic gap from the electrical contacts, thus allowing for a higher current capacity. A typical switch of this type is described in US. Patent No. 3,317,869.

Both of the foregoing types of switches have an inherent normally open type of operation. They can, however, be made to operate as normally closed switches by using a permanent bias magnet to hold the switch closed normally, and having an operating coil that opposes the bias magnet and causes the switch to open when the coil is actuated.

Relays suitable for use in many industrial control circuit applications have been constructed of groups or assemblies of scaled contact switches with a common coil. The coil and switches usually are assembled in a unitary housing, and in some cases there is provision for having some switches operate in normally open fashion While others are normally closed. Many of the prior constructions are not fully satisfactory, however, especially for industrial control applications, either because of lack of flexibility or because of general operating deficiencies.

SUMMARY OF THE INVENTION It is one primary object of this invention to provide a multiple sealed contact switch relay especially suited for industrial control circuit applications in which the several switches are disposed in separately removable modular cases to provide a maximum of flexibility and versatility at the site of use.

Another primary object is the provision of a multiple switch relay including magnetic flux concentrating means defining desired flux paths and insuring effective operation of the several switches.

Other primary objects include the provision of a relay that is uniquely effective, compact, versatile and durable, relatively inexpensive to manufacture and easy to assemble and use.

Still other objects and advantages will become apparent from the following description in which there is shown, by way of illustration and not of limitation, a preferred embodiment of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a side view in elevation of a relay embodying the invention,

FIG. 2 is a top plan view of the relay shown in FIG. 1,

FIG. 3 is a somewhat enlarged view in cross section through the plan 44 indicated in FIG. 10,

FIG. 4 is a somewhat enlarged view in cross section through the plant 44 indicated in FIG. 10,

FIG. 58 together constitute an exploded showing of the relay of FIG. 1, in which:

FIG. 5 is a view in perspective of a frame forming a part of the housing of the relay,

FIG. 6 is a view in perspective of the operating coil of the relay,

FIG. 7 is a view in perspective of a group of modular switch cases forming a part of the relay, some of which are shown in phantom lines and one of which is shown partially broken away,

FIG. 8 is a view in perspective of a clamp forming a part of the housing of the relay,

FIG. 9 is a view in perspective on a somewhat smaller scale than FIG. 4 of a modified modular switch case,

FIG. 10 is a fragmentary view of a relay similar to the one shown in FIG. 2 but showing the relay including a modular alternating current rectifier case, and a modified modular switch case of the type shown in FIG. 9, and

FIG. 11 is a somewhat schematic view in cross section through the plane 11-11 indicated in FIG. 10.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring first to FIGS. 1 and 5, the relay comprises a housing which includes a generally channel shaped frame 1 which is formed of a magnetic metal. The frame 1 includes a central floor 2, edge portions of which are offset to define opposite horizontal shoulders 3. Extending upwardly from the shoulders 3 are opposite, parallel side walls 4. The upper margins of the side walls 4 are turned in to define ledges 5 that overhang the shoulders 3. As shown in FIG. 5, an end wall 6 extends upwardly from one end of the floor 2. The end wall 6 is provided with a rectangular aperture 7 just beneath the upper margin thereof.

A pair of tabs 8 extend outwardly from opposite sides of the floor 2. The tabs 8 include, respectively, a notch 9 and an aperture 10 which provide means for mounting the relay, for example on a control panel. As seen best in FIG. 5, there are slots 11 formed under the shoulders 3 at the open end of the frame 1, or in other words the end opposite the wall 6. The shoulders 3 also include threaded openings 12 above the slots 11. 1

Referring now to FIG. 6, there is shown a molded operating coil 13 of suitable electrical characteristics which has a generally rectangular overall configuration. The coil 13 has a vertical opening 14 therethrough, which is also of rectangular shape, and the coil winding 15 encircles the opening 14. The coil 13 has opposite upper fore and aft surfaces 16 and similar lower fore and aft surfaces 17. To complete the coil 13, a pair of terminals 18 are provided at an upper end thereof and are adapted to be connected to a suitable power supply, which can be either a simple direct current supply or a full wave rectifier alternating current supply.

Referring now to FIGS. 3 and 7, the preferred embodiment shown includes a group of eight individual, separately removable modular switch cases 19 fomed of a suitable moldable insulating material. Each case 19 encloses a magnetically operable sealed contact switch 20. Each case 19 comprises a molded body 21 with a hollow, compartmentalized interior. The body 21 includes a side wall 22 as an integral part thereof. A second, similar side wall 23 is formed of a separate sheet of material and fitted to the body 21 to completely enclose the interior thereof, this mode of construction providing for ease in manufacture and assembly.

The body 21 of each switch case 19 has an enlarged head portion 24, and a reduced lower portion 25 adapted to be received within the coil opening 14. A pair of spaced conductive terminals 26 are mounted in suitable recesses in the head portion 24 of the body 21 and are preferably in the stepped relationship shown with one above and behind the other to provide easy accessibility as well as electrical spacing or separation. The terminal members 26 of each modular case 19 are also insulated from terminal members of adjacent modular cases by means of the insulating side walls 22, 23 and a back Wall 27 of the body 21. The terminal members 26 are provided with terminal screws 28, and are electrically connected to opposite leads of the associated sealed contact switch 20 by jumpers 29.

As shown in FIGS. 3 and 5, the forward surface of the head portion 24 of each switch case 19 is provided with a transverse groove 30 which slidingly receives the inwardly turned overhanging ledge of the side wall 4 when the relay is assembled.

Referring to FIGS. 3 and 7, the reduced portion 25 of each body 21 defines an elongated vertical chamber 31 which receives one of the magnetically operable sealed contact switches 20. In the embodiment shown, the switches are of the type shown in the aforementioned US. Patent No. 3,317,869, but ordinary reed switches may of course be substituted. The switches 20 are of the usual, normally open type, and include outward extending leads 32 which are connected to the jumpers 29.

Mounted in chamber 31 on opposite sides of the sealed switches 20 are an upper fiux concentrator 33 and a lower flux concentrator 34. The concentrators 3-3 and 34 are formed of suitable magnetic material and have similar curved or semi-tubular configurations. The two concentrators 33, 34 are wrapped partially around the associated switch 20 and extend upwardly and downwardly, respectively, from the vicinity of the magnetic operating gap of the switch 20. The concentrators 33, 34 define a preferred flux path and concentrate magnetic flux across the magnetic gap of switch 20 to insure that it will operate upon actuation of the coil 13. The bottom portion 35 of the lower concentrator 34 extends through the bottom wall 36 of chamber 31 to contact and rest upon the frame floor 2 when the relay is assembled. The back wall 27 of the body 21 is provided with a transverse groove 37, and the top portion 38 of the upper concentrator 33 extends into the groove 37.

Referring now to FIGS. 1 and 2 and particularly to FIG. 8, the relay housing also includes a releasable clamp 42. The clamp 42 has an overall L-shaped configuration with a 'body portion 43 that is of rectangular shape to extend across the open end of frame 1. A foot 44 is formed on the bottom margin of the body portion 43 and extends inwardly therefrom. The foot 44 is provided with toes 45 having openings 46. The toes 45 are received in the slots 11 under the shoulders 3. Once the toes 45 are inserted, the openings 46 are aligned with the threaded Openings 12 on the shoulders 3. The clamp 42 is also provided with a channel-shaped arm 47 which extends inwardly from the upper margin of body portion 43. Clamp 42 is also made of a suitable magnetic material such as cold-rolled steel.

To assemble the relay, the eight cases 19 are first arranged in two back-to-back banks of four each, as shown in FIG. 7, and are then inserted within the coil opening 14 from the top. The reduced lower portions 25 of the several cases 19 together form a rectangular block which fits within coil opening 14 tightly enough to prevent substantial misalignment. The head portions 24 extend above opening 14 and overhang and lie on the upper fore and aft surfaces 16. Thus, the switches 20 housed in the several modular cases 19 are arranged along the interior circumference of the coil 13 and positioned closely adjacent to said coil, to be aligned with the magnetic field generated by the energization of the coil 13. The modular cases 19 of course can be removed or replaced individually as desired.

The assembled coil 13 and cases 19 are then inserted in the open end of frame 1. The transverse grooves 30 on the forward surfaces of the head portions 24 slidingly receive the inwardly turned ledges 5 of the side walls 4 during insertion; and the lower fore and aft surfaces 17 of coil 13 contact and slidingly move over the shoulders 3 as the coil 13 and cases 19 are slid into place. The end wall 6 of frame 1 serves as a stop to insure proper orientation. The ledges 5 block Withdrawal of the assembled coil 13 and switch cases 19 in an upward direction, and the spacing between the ledges 5 and shoulders 3 is such as to hold the elements tightly in place. In the embodiment shown, the coil terminals 18 are formed so as not to prevent their end of the coil 13 from being inserted into the frame 1 first should that be desired or convenient.

When the cases 19 are assembled as shown in FIG. 7, the grooves 37 are aligned and together define a rectangular passage through the group of cases 19. The clamp arm 47 is inserted into this passage, and is received therein with a relatively tight fit. The arm 47 extends across the top of the coil 13 from the open end of frame 1 to the closed end, and is received through the end wall aperture 7. The arm 47 contacts the top portions 38 of the upper flux concentrators 33 that protrude into the grooves 37 from the switch case chambers 31, and provides additional means to block upward vertical movement of the assembled coil 13 and cases 19.

When the clamp arm 47 is fully inserted in the aforesaid passage, the clamp body portion 43 extends across and closes oif the open end of the frame 1. The toes 45 on body portion 43 are then received in the slots 11 under the shoulders 3 with the openings 12, 46 in alignment. The clamp 42 and frame 1 are then releasably connected together by screws 48 or other suitable means passing through the openings 46 and 12.

When the relay is assembled, the bottom portions 35 of the lower flux concentrators 34 contact the frame floor 2. The floor 2, end wall 6, clamp arm 47 and clamp body 43 together define a closed magnetic flux path which contacts and interconnects the concentrators 33, 34.

In FIGS. 4, 9 and 10, there is shown a second, modified type of switch case which is numbered 19a and which is used when a normally closed switch is desired. The switch cases 19 and 19a are similar in many respects, the case 19a being essentially like two cases 19 back-to-back, and the case 19a can be constructed like the cases 19 with one integral side wall and one attached wall or in any other convenient fashion. Instead of having two chambers 31 and switches 20, however, case 19a has one chamber 31 and switch 20 (with concentrators 33, 34) and a second,

modified chamber 31a which constitutes an extension of chamber 31 and which receives a permanent magnet 39 that lies alongside the switch 20. The permanent magnet 39 develops a magnetic field which normally holds the switch 20 closed. The orientation of the magnet 39 is such that its field is opposite to the field generated by thecoil 13, however, so that when coil 13 is energized it overcomes the effects of the magnet 39 and causes the switch 20 to open. A pair of shields 40 of a suitable material are provided on each side of the magnet 39 in chamber 31a. The purpose of such shields 40 is to prevent interference in the operation of switches 20 in adjacent switch cases by the permanent magnet.

The modular case 19a includes a head portion 24 on one side and a similarly shaped dummy upper head portion 24a on the other. The switch case 19a is provided with a passageway 41 therethrough, which is similar to two grooves 37 back-to-back, and the top portion 38 of the upper concentrator 33 projects into the passageway 41. The case 19a thus has substantially the same size and configuration as two cases 19 disposed back-to-back. One case 19a containing a normally closed switch 20 can, therefore, be substituted for two cases 19 in this group of switches, and cases 19a can be used in combination with or in lieu of cases 19 to the extent appropriate for any particular circuit. It is contemplated that switch case 19a can be converted to perform a conventional latching function if desired.

Any one or more sets of back-to-back switch cases 19 can easily be removed and replaced with a modified case 19a merely by following the reverse of the aforedescribed simple assembly procedure. This allows for great flexibility and versatility in meeting circuit requirements at the site of use.

Where only an alternating current supply is available, the relay can be provided with a modular case 49 that encloses full wave alternating current rectification means 50, which can be of any of the several suitable types known to those skilled in the art. The outline and configuration of case 49 is similar to modified switch case 19a, the case 49 also being provided with a passage 51 for receiving the clamp arm 47. The case 49 includes input terminals 52 for connection with the alternating current supply, and output terminals 53 from which the full wave rectified current is supplied to the coil terminals 18 through jumpers 54 connected therebetween. The terminals 52, 53 are positioned in stepped relationship similar to the terminals 26. Although the modular rectifier means shown is extremely convenient, the full wave rectification of alternating current can be accomplished externally of the relay.

The operation of the relay assembly may now be summarized. In a normal, unenergized condition of the coil 13, the switches 20 positioned in the relay in individual modular cases 19 or 19a are either opened or closed depending on the type of switch and modular case used. Upon energization of the coil 13, the switches 20 are closed or opened respectively in response to magnetic flux across the magnetic gap area thereof. The upper concentrators 33 and lower concentrators 34 in the switch case chambers 31 serve to establish a desired concentrated flux path in the area of the magnetic gap of the switches 20, thus insuring effective operation. The closed magnetic path formed by the clamp 42 and frame 1 further insures a highly effective operation.

In keeping with the general provisions of the invention, therefore, a relay is provided in which individual, separately removable switch modules can be quickly and easily replaced or changed to provide either normally open or normally closed operation. The mangetic flux paths set up by the housing members and concentrators insure effective operation, and the relay is generally rugged and effective, while being relatively simple and inexpensive.

Although a specific structural form of this invention has been illustrated and described, the invention is not limited to the specific construction herein disclosed and it is expected that those skilled in the art may be able to devise changes in or alternatives to the disclosed structural features while still practicing this invention. It is contemplated, for example, that various types of sealed contact switches could be used in the relay, or even that other types of equivalent magnetically operable switches could be used. It is to be understood, therefore, that it is intended by the following claims to cover all changes and modifications in the illustrated embodiment of this invention herein disclosed, as well as other embodiments not disclosed, which do not constitute a departure from the true spirit and scope of this invention.

I claim:

1. In a relay the combination comprising: an operating coil defining opposite, parallel sides; a plurality of modular switch units assembled with the coil, each switch unit comprising an elongated case with a reduced body portion and an enlarged head presenting a pairof forwardly facing terminals which are stopped upwardly from front to rear, each switch unit including an elongated, magnetically operable reed switch disposed in the body portion of the case with one end near the head, there being a connector between said one end of the switch and one of the terminals and a second connector leading from the other end of the switch to the other terminal, which second connector is disposed in the case alongside the switch, the switch units being arranged in two banks which face respective sides of the coil, each bank comprising a plurality of switch units in an aligned, side-byside relationship, the two banks being in an aligned relationship with the backs of the two banks facing one another and with the heads of the units of both banks all on the same side of the coil but with the heads of the units of the two banks facing outwardly in opposite directions, the switches all being axially aligned with the coil to be operable thereby; and housing means to releasably hold the switch units and coil in assembled relationship.

2. The combination of claim 1 wherein there are a plurality of aligned pairs of elongated magnetic flux concentrator plates, one pair being adjacent each switch with the members of the pair parallel to and associated with respective reeds to define a magnetic flux path across the magnetic gap of the switch.

3. The combination of claim 2 wherein the pairs of concentrator plates each comprise an upper member at one end of the coil and a lower member at the other end of the coil; and the upper ends of all the upper members are magnetically connected; and the lower ends of all of the lower members are magnetically connected.

4. In a relay the combination comprising: an operating coil having a central vertical opening therethrough; a plurality of modular switch cases, each case having a reduced lower portion and an enlarged head, the cases being arranged in two back-to-back banks with the reduced portions received in the coil opening from the top and axially aligned with the coil and the heads of the cases overhanging the coil from above; a plurality of magnetically operable switches, one disposed in the lower portion on each case, the switches all being aligned with the magnetic field of the coil to be operable thereby; flux concentrating means alongside each switch to define a magnetic flux path across the magnetic gap thereof; and a housing to hold the coil and switch cases in assembled relationship, said housing including a frame adapted to be mounted on a panel or the like and having a floor, opposite side walls, one end wall and an open end, the coil and switch cases being movable as an assembled unit into and out of said frame through the open end thereof toward and away from an assembled position in which the bottom of the coil is against the floor, the heads of the cases including means engageable with the frame side walls when the cases and coil are in assembled position to restrain movement of the cases and coil in a direction normal to and away from the housing floor, the housing also including a releasable clamp connectable to the frame to hold the assembled coil and cases against movement out of the frame.

5. The combination of claim 4 wherein:

the side walls have inwardly extending overhanging retaining ledges;

the coil is interposed between said retaining and said floor; and the heads of said modular switch cases include grooves which receive said ledges to restrain the coil and cases against movement normal to the floor.

6. The combination of claim 4 wherein said clamp includes a wall that extends across the open end of the frame and an arm extending normally therefrom and across the top of said coil opening to releasably engage the end wall of the frame; and the back of the modular switch cases in the banks are provided with adjacent opposing grooves defining an opening to receive said arm.

7. The combination of claim 6 wherein: the frame ledges and clamp are formed of a magnetic material; and each modular switch case contains two magnetic flux concentrating plates positioned on opposite sides of an associated switch and leading in opposite directions from the area of the magnetic gap thereof, an end of one plate protruding from the bottom of said case to contact the floor of the frame, and an end of the other plate protruding into said groove to contact said arm.

References Cited 7 UNITEDSTATES PATENTS 3,030,468 4/1962 Doncell et al. 335l52 3,121,147 2/1964 Dal Bianco et a1. 335151 X 3,170,089 2/1965 Zielinski 335-152 X 3,190,985 6/1965 Pearse et a1. 335152 X BERNARD A. GILHEANY, Primary Examiner R. N. ENVALL, JR., Assistant Examiner Disclaimer 3,508,180.Joseph 0. Mag er, Milwaukee, Wis. RELAY VITH SEALED CONTACT SWITCH MODULES. Patent dated Apr. 21, 1970. Disclaimer filed Sept. 17, 1970, by the assignee, Allen-Bradley Oomprmy. Hereby enters this disclaimer to claims 1, 2 and 3 of said patent.

[Ofiioial Gazette November 17, 1970.] 

